Power-driven continuous cutting strip and method of utilization thereof

ABSTRACT

A flexible cutting strip including stabilizing portions operable to slidably engage a ringlike base and cutting teeth formed integrally with one base. A method of cutting wherein a flexible cutting strip is constrained to follow a circular and continuous cutting path so as to prevent flexing of the cutting strip and where a circular support follows and supports the strip as it is moved into a kerf.

United States Patent Inventor Jack W. Ehlen Torrance. Calif. Appl. No. 848,049 Filed Aug. 6, 1969 Division of Ser. No. 605.371. Dec. 28. 1966. Pat. No. 3.468.351. Patented July 6, 1971 Assignee McCulloch Corporation Los Angeles, Calif.

POWER-DRIVEN CONTINUOUS CUTTING STRIP AND METHOD OF UTILIZATION THEREOF 4 Claims, 7 Drawing Figs.

US. Cl 143/133, 144/312,144/323,143/135 Int. Cl B27b 33/06, B271: 1/00 Field of Search 143/44, 32,

[56] References Cited UNITED STATES PATENTS 2,958,348 11/1960 Blueneman 143/139 2,972,363 2/1961 Santilli 143/44 3,338,275 8/1967 Ehlen 143/32 3,373,489 3/1968 Giles 143/44 3,395,741 8/1968 Miller 143/32 X Primary Examiner-Donald R. Schran An0rneyBurns, Doane, Swecker & Mathis ABSTRACT: A flexible cutting strip including stabilizing portions operable to slidably engage a ringlike base and cutting teeth formed integrally with one base.

A method of cutting wherein a flexible cutting strip is constrained to follow a circular and continuous cutting path so as to prevent flexing of the cutting strip and where a circular support follows and supports the strip as it is moved into a kerf.

PATENTED JUL slsn W m 2 3590.892

INVENTOR JACK W4 EHLEN BY MM MA ATTORNEYS PATENTED JUL 6 19m SHEET 2 BF 2 FIG? INVENTOR 74 72 20 JACK w. EHLEN BY gun and A.-f6.,'

ATTORNEYS POWERDRIVEN CONTINUOUS CUTTING STRIP AND METHOD OF UTILIZATION THEREOF CROSS-REFERENCE TO RELATED APPLICATION This application is a division of U.S. Pat. No. 3,468,35l, which matured from application Ser. No. 605,371, filed Dec. 28, 1966, which patent is assigned to the assignee of this application.

While this application involves several novel concepts, it is related in part to the subject matter of U.S. Pat. No. 3,338,275.

BACKGROUND OF THE INVENTION The previously mentioned US. Pat. No. 3,338,275 discloses a portable powersaw comprising a continuous cutting strip which is driven by a driving wheel about the periphery of an elongated support member having a curved end. The driving member is driven by the power motor and is disposed inside the periphery of the continuous cutting strip to drivingly contact portions of the cutting strip.

A powersaw constructed in accordance with US. Pat. No. 3,338,275 has been found to provide substantial advantages over a conventional chain saw. For instance, the relatively flexible, continuous cutting strips may be very economically manufactured, as by stamping, and may thus be thrown away when dull rather than necessitating removal and sharpening. Because of the low inertia resulting from the light weight of the continuous cutting strip, such a portable power saw may be virtually instantaneously stopped, thus allowing for ease of operation and reducing the hammering often created by conventional chain saws. Further, the continuous cutting strip does not tend to carry a substantial amount of foreign material between the cutting teeth during a cutting operation, and the strip does not then significantly stretch. Because of its continuous smooth base surface, the continuous strip is easily installable or repaired, and provides a smooth outward flow of chips during a cutting operation.

While a powersaw constructed in accordance with the previously mentioned U.S. Pat. No. 3,338,275 provides excellent cutting characteristics in many respects, it has been found that the continuous cutting strip of such saws is sometimes subjected to wear due to the flexing imposed upon the strip by the elongated curved support member.

Additionally, since in such saws the driving member is disposed inside the periphery of the continuous cutting strip, it has been found that the continuous strip sometimes tends to move away from the driving member upon the occurrence of substantial cutting forces. The driving member also sometimes tends to bend or kink the continuous cutting strip if the strip becomes bound or locked into the material being cut.

OBJECTS OF THE INVENTION Accordingly, a general object of the present invention is the provision of a method and apparatus for cutting which minimizes or substantially eliminates disadvantages heretofore present in powersaw cutting.

A more specific object is the provision of a portable powersaw wherein flexing of the cutting member is substantially eliminated.

A further object of the present invention is the provision of a cutting device wherein the drive maintains driving contact with the cutting member even during the application of substantial cutting stresses.

Yet a further object of the present invention is the provision of an improved cutting device having a very lightweight and economical, yet efficient, continuous cutting member.

It is a still further object of the present invention to provide a cutting device which does not tend to retain or carry substantial amounts of foreign material between the cutting teeth during cutting to reduce stretching of the cutting device.

Another object of the present invention is to provide a continuous cutting device having an interrupted surface to provide a smooth outward flow of chips during a cutting operation.

Yet another object of the present invention is to provide an easily installable cutting member which does not tend to kink.

It is a further object of the invention to provide a cutting member wherein the individual cutting elements are integral with the cutting member in order to eliminate rear back and to substantially eliminate twisting of portions of the cutting member.

It is a still further object of the present invention to provide a cutting device which may be virtually instantaneously stopped because of relatively low inertia.

Another object of the present invention is to provide a cutting device which due to low frictional losses does not generate a substantial amount of heat.

A still further object of the present invention is the provision of a cutting device wherein the tension of the rotating cutting member may be selectively adjusted.

SUMMARY OF THE INVENTION In achieving these and other objects which will be apparent hereinafter, one aspect of the present invention provides a support defining a substantially circular and continuous travel path, with a radially flexible continuous cutting strip rotatably disposed in the travel path. The cutting strip may include a plurality of integral cutting teeth bent transversely. Driving means rotates the cutting strip through the substantially circular travel path.

Another aspect of the present invention provides a flexible cutting strip having a generally flat base portion with a plurality of transversely spaced cutting teeth pairs integrally inclined from the base portion.

Another important aspect of the present invention comprises a method of cutting wherein a radially flexible continuous cutting strip is supported and driven about a continuous circular travel path to prevent flexing of the cutting strip.

THE DRAWINGS The invention and its many advantages may be further understood by reference to the following detailed description illustrated in the accompanying drawings, in which:

FIG. 1 is a side view of a portable powersaw constructed in accordance with the present invention;

FIG. 2 is a side view of a preferred embodiment of a portion of the cutting strip of the present invention;

FIG. 3 is a top view of a preferred embodiment of another portion of the cutting strip of the present invention;

FIG. 4 is a detailed side view of the cutting strip driving portion of the present invention;

FIG. 5 is a cross-sectional view of the driving mechanism taken along the lines 5-5 of FIG. 4;

FIG. 6 is a cross-sectional view of the support adjustment taken along lines 6-6 of FIG. 4; and

FIG. 7 is a cross-sectional view of a portion of the lubrication system of the present invention taken along lines 7-7 of FIG. 4.

DETAILED DESCRIPTION OF THE INVENTION Referring to FIG. I, a portable saw constructed in accordance with the present invention is powered by a conventional gasoline motor designated generally at 10 and having a pair of handles 12 and 14. The gasoline motor I0 may be conventionally started by manual operation of the starter 16.

Rigidly connected to a support extension 18 is a hollow circular support member 20 which defines a substantially circular and continuous travel path for a continuouscutting strip 22. The cutting strip 22 is constructed from relatively thin metal to be radially flexible and is thus incapable of withstanding the forces of cutting without the support member 20. The support member 20 may be made from 7075 ST heat-treated aluminum about 0.141 inches thick. In the preferred embodiment, an outer diameter of about I 1.46 inches for the support member 20 has been advantageously utilized. The cutting strip 22 is driven about the support member 20 by a drive sprocket wheel 24 which is disposed outside the periphery of the strip 22 and is rotated by a suitable drivebelt 26. The gasoline engine l powers a driving shaft 28 which in turn rotates the drive sprocket wheel 24 through drivebelt or chain 26.

A shield member 30 is provided to protect the saw operator from the rotating drive sprocket wheel24. Guard members 32 and 34 are rigidly connected to the support member by suitable fastening screws 35 in order to shield the cutting edges of the rotating cutting strip 22. An adjusting screw 36 is disposed through an elongated slot 38 to connect one end of the circular support member 20 to the extension 18. By adjustment of the position of screw 36 in slot 38, the magnitude of the generally circular travel path provided by the outer periphery of the support member 20 may be varied to allow selective adjustment of the tension of the rotating continuous cutting strip 22. The support member 20 is provided with an expandable joint 40, to be later described in more detail, to allow such adjustment while maintaining a continuous travel path. An outwardly extending bumper 42 may be suitably connected to the support member 20 to provide a stop or pivot point about which the cutting device may travel during a cutting operation.

The continuous cutting strip 22 includes a plurality of integral cutting teeth 44 for performing efficient cutting operations, as will be later more fully described. Additionally, the cutting strip 22 includes a plurality of spaced apart integral guide members 46 for encompassing a portion of the outer periphery of the circular support member 20 in order to constrain the cutting strip 22 to follow the substantially circular travel path and prevent flexing of the strip. It has been found that significantly longer wear and lower frictional losses are provided by this aspect of the present invention.

FIG. 2 discloses in detail a portion of a preferred embodiment of the present cutting strip 22. Each of the cutting teeth 44 have identical cross-sectional configurations and are integrally connected with a relatively flat base portion 48. The cutting teeth 44 are bent transversely of the base portion 48 at predetermined inclinations. Each cutting tooth 44 includes a sharpened cutting surface 50 which may be slightly backwardly inclined in a trailing manner. it will be understood, however, that the cutting surface 50 could be posi tioned either at a right angle with the base portion 48, in a forwardly inclined leading position, or in combinations of all three positions. As will be later described in detail, a driving surface 52 is also provided for each of the cutting teeth 44 to enable the flexible cutting strip 22 to be driven by the rotating drive sprocket 24.

The guide members 46 integrally connected to the flat base 48 are constructed with an identical cross-sectional configuration as the cutting teeth 44. This identical construction of both the cutting teeth and guide members enable the present device to be easily manufactured, as by stamping from a single piece of metal. The guide members 46 are transversely disposed in pairs along the flat base 48, with each pair being bent radially inwardly from the base 48 to define a space for encompassing a portion of the outer periphery of the support member 20 to constrain the cutting strip 22 to follow a substantially circular travel path.

FIG. 3 shows a top view of a preferred embodiment of inclining configurations for the cutting teeth of the present cutting strip 22. The cutting teeth comprise a plurality of pairs of transversely spaced cutting teeth integrally connected to the flat base portion 48. in order to provide superior cutting characteristics, the cutting teeth pairs may be longitudinally grouped along and bent relative to the base portion 48 in recurring series of four different inclining configurations.

A first inclining configuration is illustrated by the cutting teeth pair 54 and 56, wherein both these cutting teeth are evenly substantially vertically inclined to the base portion 48.

In practice, it has been found that a base portion 48 having a width of about 0.232 inches in combination with an outward spacing of about 0. l 68 inches from the top of the cutting tooth 54 to the top of cutting tooth 56 provides excellent cutting characteristics.

A second inclining configuration is illustrated by the positions of the cutting teeth pair 58 and 60, wherein each of the cutting teeth are evenly transversely inclined to the base portion 48 by a greater amount that the first inclining configuration of cutting teeth 54 and 56. In practice, a spacing of about 0.336 inches from the top of cutting tooth 53 to the top of cutting tooth 60 has been advantageously utilized.

In the third inclining configuration illustrated by the position of cutting teeth 62 and 64, the cutting tooth 64 is inclined more so on a first side of the base portion 48 than the cutting tooth 62 of the teeth pair. In practice, the cutting tooth 64 is bent to a position slightly past the ccnterline of the flat base 48, while the cutting tooth 62 is inclined only slightly more outwardly than the cutting tooth 54.

The fourth inclining cutting teeth configuration of the present invention is illustrated by the positions of the cutting teeth 66 and 68. The cutting tooth 66 is inclined more so on a second side of the base portion 48 than cutting tooth 68. The configuration of cutting teeth 66 and 68 is opposite the configuration of cutting teeth 62 and 64, with the top of cutting tooth 66 being bentjust slightly past the center of the flat base portion 48. The inclination of cutting tooth 68 to the flat base 48 is only slightly more outwardly inclined than the cutting tooth 56 previously described. l

The continuous cutting strip 22 may be constructed from a single piece of low carbon, SAW l030l050 steel that has been Austempered and cyanide hardened. Carbon may be added to the surface of the strip so that Austempering will yield an improved hardened cutting edge. Alternately, the top of the stamped out cutting strip may be copper masked before cyanide hardening in order to provide harder surfaces on the inside of the guide members and on the outside of the cutting teeth.

The ends ofthe present cutting strip 22 may be easilyjoined during manufacture or repaired upon breaking. For instance, a Thermite process may be used to join the ends of the strip. Alternatively, the ends of the strip may be secured together by electric fusion welding, by butt welding, or by brazing with a short overlap.

Although recurring series of four different inclining configurations are illustrated, it will be understood that recurring series of more or less than four inclining configurations may' also be advantageously utilized. Further, a cutting strip constructed in accordance with the previously discussed US. Pat. No. 3,338,275 may be utilized with the present saw. With the provision of the present cutting teeth inclining configurations, it has been found that the continuous cutting strip 22 is less likely to bind in the material being cut. Further, a cutting strip constructed in accordance with this invention does not tend to retain or to carry substantial amounts of foreign material between adjacent cutting teeth during cutting and thus stretching of the cutting strip is reduced. Also, due to the open space between the transversely spaced cutting teeth and due to the continuous surface provided by the flat base 48, the cutting strip of the present invention provides a smooth outward flow of chips during the cutting operation.

Referring now to FIG. 4, wherein like reference numerals refer to like and corresponding parts previously described, the driving mechanism for the cutting strip 22 is illustrated in greater detail. The drive sprocket wheel 24 rotates in a counterclockwise direction and includes a plurality of radially outwardly extending sprockets 70 for drivingly engaging the driving surfaces 52 of the cutting teeth 44. In the preferred cmbodiment the sprocket wheel 24 was constructed-with awidth of about 0.375 inches and an outside diameter of about 2.14 inches, sprocket to sprocket.

Each sprocket 70 contacts a cutting tooth near the junction of the cutting tooth with the flat base portion 48 of the cutting strip 22, but the sprockets 70 are so dimensioned to leave a small clearance between the end of the sprocket and the flat base portion 48. As the sprocket wheel 24 is rotated, a sprocket 70 moves upwardly from the base of a cutting tooth driving surface 52 to propel the cutting strip 22 forward. Just as the cutting tooth contacting sprocket clears the top of the cutting tooth, the next sprocket 70 contacts the base of the next cutting tooth to provide a continuous drive of the cutting strip 22. It should be noted that although the preferred embodiment illustrates a rotating drive wheel disposed outside the periphery of the flexible cutting strip 22, the drive wheel could be disposed inside the periphery of the strip and drivingly contact the guide members.

The slope of the cutting teeth driving surfaces 52 cause the force vectors provided by the sprockets 70 on the driving surfaces 52 to be so directed as to push the cutting strip 22 against the outside periphery of the support member to provide a positive drive of the cutting strip. By varying the slope of the cutting teeth driving surfaces 52, the direction of the force vectors of the sprockets 70 may be changed, thus also changing the magnitude of the driving tension placed upon the cutting strip 22. Further, because the sprocket wheel 24 is disposed outside the periphery of the rotating cutting strip 22, a continuous drive is maintained against the cutting strip even upon the occurrence of substantial cutting forces. The present driving mechanism for the circular saw does not tend to bend or kink the cutting strip 22 when the cutting teeth become bound or locked into the material being cut. The uniform drive provided by the driving sprocket wheel reduces wear and bending loads on the cutting strip to allow the use of thinner band steel. As previously discussed, the sub stantially circular and continuous travel path provided by the support member 20 reduces flexing of and thus provides a longer life for the cutting strip 22.

To further reduce frictional losses, lubricant may be supplied between the support member 20 and the cutting strip 22. A constant flow of lubricant may be conventionally supplied to a chamber 72 (FIGS. 4 and 7) and then through a passage 74 to circumferential groove 76 disposed around the support member 20. Due to the rotary motion of the cutting strip 22 and pressure supplied to the lubricant, a thin film of lubricant is disposed about the periphery of the support member 20 in order to substantially reduce frictional losses of the saw. As shown in greater detail in FIG. 7, the lubricant may be supplied by a conventional pump arrangement through channels 78 and 80 into the lubricant chamber 72.

Referring to FIGS. 4 and 5, the internal construction of the drive mechanism for the sprocket wheel 24 is illustrated. Portions of the drivebelt or chain 26 engage with teeth of a drive wheel 82 which is journaled in the support extension 18 by suitable bearing members 83. A guard housing 64 is connected to the extension 13 by suitable screws 86 and is disposed over the wheel 82 for safety. The drive wheel 82 fits through the sprocket wheel 24 and is connected to rotate the wheel 24 by a key member 88. A suitable fastening nut 90 is provided to suitably tension the sprocket wheel 24 on the rotating drive wheel 82. As previously described, the guide members 46 encompass portions of the periphery of the support member 20 to constrain the cutting strip 22 to follow a circular travel path.

FIGS. 4 and 6 clearly illustrate the interlocking expansion joint 40, which is located below the contact point of the sprocket wheel 24 with the cutting strip 22 in order to prevent undue stress upon the expansion joint. One end of the split circular support member 20 is firmly connected to the support extension 18 by a suitable fastening device 35. The fixed end of the circular support member 20 is provided with an extension 92 which defines a slot portion 93. The adjustable end of the split support member 20 includes a mating extension 94 which closely fits into slot portion 93 and which defines a slot portion 95 for matingly receiving extension 92. The ends of the extension 92 and 94 are beveled, and the slot portions 93 and 95 have beveled shoulders to mate with the extension ends when the joint is fully interlocked. By selective positioning of the screw 36 in the elongated slot 38, the magnitude of the outer periphery of the circular support member 20 may thus be adjusted in magnitude in order to select the desired tension for the cutting strip 22, while maintaining a substantially continuous circular travel path. A spring may be disposed in the slot 38 to provide continuous tension to the adjustable end of the support member 20.

From the foregoing detailed description, it will be apparent that a powersaw constructed in accordance with the present invention provides substantial advantages over powersaws heretofore developed. For instance, the relatively flexible con tinuous cutting strip of the present invention may be very economically manufactured and may thus be thrown away when dull without necessitating time consuming sharpening. Because of its low inertia, the present saw may be virtually instantaneously stopped. The present cutting strip does not stretch even with substantial use and provides a smooth out ward flow of chips during the cutting operation.

As is apparent from the cross-sectional illustration of the guide bar 20 and cutting strip 22 presented in FIG. 5, and the overall arrangement of these components as shown in FIG. 1, the guide bar or rigid means 20 is fully operable to follow the flat base or support means 48 of the strip 22, as the strip 22 moves into a kerfcut by cutting teeth 44.

As will also be apparent, in view of the foregoing discussion and the appended drawings, the various cutting teeth 44 are connected to the base 48 by connecting the sheet metal portions 440. These connecting portions 44a, as illustrated and described, are integral portions of the strip 22 and are sup ported immediately adjacent the guide bar 20 for substantially nonflexing movement through the circular travel path defined by the guide bar periphery.

Additionally, a powersaw constructed in accordance with the present invention eliminates flexing of the continuous cutting strip and thus provides a longer life of the saw because of the low frictional losses and low heat generation. The present saw is extremely easy to lubricate, and in fact requires less lubrication because of its novel method of construction and operation. Because of the provision of the novel expansion joint of the circular support member, tension on the cutting strip may be selectively adjusted while maintaining a continuous travel path for the cutting strip.

It will be understood that while a preferred embodiment has been described, the invention should not be limited to the exact method or apparatus illustrated, as various modifications which do not depart from the essence of the invention will be obvious to those skilled in that art.

What I claim is:

l. A flexible cutting strip comprising:

a generally flat, elongated and flexible base portion, with said base portion having a width exceeding its thickness and with said width being adapted to be at least partially coextensive with a kerf base;

a plurality of cutting teeth formed integrally with and inclined transversely of said base portion;

said teeth being longitudinally grouped along said base portion in a series of recurring pairs of teeth spaced transversely of said width;

at least some of said teeth overlapping said flat base portion and being operable to cut a kerf base;

said teeth pairs being longitudinally grouped along said base portion in recurring pairs of different inclining configurations, with the teeth thereof being substantially flat and planar in configuration; and

at least one of said inclining configurations comprising an arrangement wherein one cutting tooth of one teeth pair is inclined more on a first side of said base portion than the other cutting tooth of the one teeth pair is inclined.

2. A flexible cutting strip as described in claim 1 wherein said pairs of teeth recur in a pattern including:

a first nonsymmetrically arranged pair of teeth, one tooth of which is inclined over and overlaps one edge of said base portion;

a second nonsymmetrically arranged pair of teeth, one tooth of which is inclined over and overlaps another edge of said base portion;

a third generally symmetrically arranged pair, the teeth of which extend generally normal to said base portion; and

a fourth pair, the teeth of which are arranged generally symmetrically and diverge outwardly and away from said base portion.

3. The apparatus of claim 1 comprising another inclining configuration wherein one cutting tooth of a second teeth pair is inclined more on a second side of said base portion than the other cutting tooth of said second teeth pair.

4. A method of cutting comprising the steps of:

slidably supporting a radially flexible continuous cutting strip on a generally circular strip-supporting means, which strip is formed of sheet metal means and is incapable of radially withstanding the forces of cutting without support by said strip-supporting means;

constraining said cutting strip to follow a substantially circular and continuous travel path;

preventing flexing of said cutting strip as it follows said substantially circular and continuous travel path; and

driving said cutting strip about said travel path and slidably about said support means while urging and following said strip into a kcrf with said strip support means relative to which said strip is moving.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3 590 892 Dated u 6 1971.

Inventor(s) It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

On the cover sheet, before "[22]" insert The portion of the term of the patent subsequent to Sept. 23, 1986, has

been disclaimed.

Signed and sealed this 22nd day of February 1972.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. ROBERT GOTTSCHALK Attesting Officer Commissioner of Patents FORM PO-1050110-69} USCOMM-DC seam-peg U 5, GOVERNMENT PRINYING OFFICE: I969 0-356-35fi 

1. A flexible cutting strip comprising: a generally flat, elongated and flexible base portion, with said base portion having a width exceeding its thickness and with said width being adapted to be at least partially coextensive with a kerf base; a plurality of cutting teeth formed integrally with and inclined transversely of said base portion; said teeth being longitudinally grouped along said base portion in a series of recurring pairs of teeth spaced transversely of said width; at least some of said teeth overlapping said flat base portion and being operable to cut a kerf base; said teeth pairs being longitudinally grouped along said base portion in recurring pairs of different inclining configurations, with the teeth thereof being substantially flat and planar in configuration; and at least one of said inclining configurations comprising an arrangement wherein one cutting tooth of one teeth pair is inclined more on a first side of said base portion than the other cutting tooth of the one teeth pair is inclined.
 2. A flexible cutting strip as described in claim 1 wherein said pairs of teeth recur in a pattern including: a first nonsymmetrically arranged pair of teeth, one tooth of which is inclined over and overlaps one edge of said base portion; a second nonsymmetrically arranged pair of teeth, one tooth of which is inclined over and overlaps another edge of said base portion; a third generally symmetrically arranged pair, the teeth of which extend generally normal to said base portion; and a fourth pair, the teeth of which are arranged generally symmetrically and diverge outwardly and away from said base portion.
 3. The apparatus of claim 1 comprising another inclining configuration wherein one cutting tooth of a second teeth pair is inclined more on a second side of said base portion than the other cutting tooth of said second teeth pair.
 4. A method of cutting comprising the steps of: slidably supporting a radially flexible continuous cutting strip on a generally circular strip-supporting means, which strip is formed of sheet metal means and is incapable of radially withstanding the forces of cutting without support by said strip-supporting means; constraining said cutting strip to follow a substantially circular and continuous travel path; preventing flexing of said cutting strip as it follows said substantially circular and continuous travel path; and driving said cutting strip about said travel path and slidably about said support means while urging and following said strip into a kerf with said strip support means relative to which said strip is moving. 